Cummins Power Generation Onan MicroLite 4000 KY Installation guide

KY

M

icroLiteTM

4000

Series

Printed

U.S.A.

2-93

981 -0627

Redistribution or publication of this document

by any means, is strictly prohibited.

Table

of

Contents

.

SECTION

TITLE

PAGE

SAFETY PRECAUTIONS

......................................

ii.

iii

1

INTRODUCTION

............................................

1-1

General

..................................................

1-1

Installation Codes and Safety Recommendations

.................

1-1

Component Locations

.......................................

1-2

2

3

4

7

8

9

10

SPECIFICATIONS

...........................................

2-1

STEP-BY-STEP INSTALLATION OUTLINE

.......................

3-1

Introduction

...............................................

3-1

Preparation

...............................................

3-1

Compartment Mounting

......................................

3-2

Under-Floor Mounting

.......................................

3-3

Connecting

to

Vehicle Systems

...............................

3-5

Exhaust System

...........................................

3-6

General

..................................................

4-1

compartment Mount

........................................

4-1

Under-Floor Mount

.........................................

4-4

VENTILATION AND ACOUSTICS

...............................

5-1

Ventilation

................................................

5-1

Acoustics

.................................................

5-2

EXHAUST SYSTEM

..........................................

6-1

General

..................................................

6-1

Muffler Recommendations

...................................

6-1

Exhaust Installation Guidelines

................................

6-1

Tailpipe Recommendations

...................................

6-1

FUEL SYSTEM

..............................................

7-1

Gasoline Fuel System

.......................................

7-1

LPG

Fuel System

..........................................

7-3

ELECTRICAL CONNECTIONS

.................................

8-1

General

...................................................

8-1

AC

Wring

................................................

8-1

DCWiring

................................................

8-5

INITIAL START

AND

CHECKS

.................................

9-1

Pre-Start Checks

...........................................

9-1

Initial Starting and Checks

...................................

9-2

Installation Review

.........................................

9-4

WIRING

SCHEMATIC/DIAGRAMS

.............................

10-1

MOUNTING

................................................

4-1

General

..................................................

7-1

i

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by any means, is strictly prohibited.

Safety

Precautions

Before operating the generator

set,

read the

Operator's Manual and become familiar with

it

and

the equipment. Safe and efficient operation can

be

achieved only

If

the

unit

is

properly operated

and maintained. Many accidents are caused by

failure to follow fundamental rules and precautions.

The following symbols, found throughout this man-

ual, alert you to potentially dangerous conditions to

the operator,

S~M'C~

personnel, or the equipment.

This

symbol

warns of immediate

hazards which

will

result

in

severe personal

lnjuv or death.

/-(This

symbol

refers to

a

hazard

or

unsafe pmctice which can result

in

severe

personal injury

or

death.

[-This

symbol

refers

to

a

hazard or

unsafe practice which can result

In

personal

injury

or product or properiy damage.

FUEL AND FUMES ARE FLAMMABLE

Fire, explosion, and personal injury can result from

improper practices.

Do

not smoke or allow an open flame

or

spark-

producing equipment near the generator set

or

fuel tank.

Fuel lines must

be

adequately secured and

free

of leaks. Fuel connection at the engine should

be

made with an approved flexible, nonconductive

line.

GASOLINE

AND

LPG FUEL MAY

BE

ACCI-

*

DENTALLY IGNITED BY ELECTRICAL

SPARKS,

presenting the hazard of fire or ex-

ploslon that can result

in

severe personal injury

or death. When lnstalllng the generator set:

4

Keep electrical and fuel lines as far

apart

as

possible. Do not allow contact unless both lines

are sheathed.

EXHAUST GASES ARE DEADLY

Never sleep in the vehicle with the generator set

running unless the vehicle is equipped with an

operating carbon monoxide detector.

Provide an adequate exhaust system to properly

expel discharged gases.

Do

not use engine

cool-

ing

air

to heat a compartment.

Be

sure the unit is well ventilated.

MOVING PARTS

CAN

CAUSE

SEVERE

PERSONAL

INJURY

OR

DEATH

Before starting

work

on

the generator set,

disconnect batteries. This

will

prevent accidental

starting and electrical arcs. Disconnect the

Negative

(-)

battery cable first to reduce the risk

of arcing.

Keep your hands away from moving parts,

Make sure that fasteners on the generator set

are secure. Tighten supports and clamps, keep

guards in position over fans, drive

belts,

etc.

Do not wear

loose

clothing

or

jewelry while

working on generator sets.

Loose

clothing and

jewelry can become caught in moving

parts.

Jewelry

can

short

out

electrical contacts and

cause

shock or burning.

If adjustment must

be

made while the unit

is

running, use extreme caution around hot

manifolds, moving parts, etc.

4

9

ii

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by any means, is strictly prohibited.

ELECTRICAL SHOCK CAN CAUSE

SEVERE PERSONAL INJURY OR DEATH

Disconnect the negative

(-)

cable

at

the starting

battery before removing protective shields or

touching electrical equipment. Use rubber

insulative mats placed on dry wood platforms on

the ground or over floors that are metal or

concrete when around electrical equipment.

Do

not wear damp clothing (particularty wet shoes)

or allow skin surfaces to be damp when handling

electrical equipment.

0

Use

extreme caution when working on electrical

components. High voltages can cause injury or

death.

0

Follow

all

state and local electrical codes. Have

all electrical installations performed by

a

qualified

electrician. Tag open switches to avoid acciden-

tal closure.

0

DO

NOT CONNECT GENERATOR

SET

DIRECTLY TO

ANY

BUILDING ELECTRICAL

SYSTEM. Hazardous voltages can flow from the

generator set into the utility line. This creates

a

potential for electrocution or property damage.

Connect only through an approved device and

after building main switch is open. Consult an

electrician

in

regard to emergency power use.

GENERAL SAFETY PRECAUTIONS

Wear safety glasses and protective clothing

when servicing batteries.

DO

NOTSMOKE while

servicing batteries. Lead-acid batteries emit a

highly explosive hydrogen gas that can be ignited

by electrical arcing

or

by smoking.

Have a fire extinguisher rated

ABC

nearby.

Maintain extinguisher properly and become

familiar with

its

use.

0

Benzene and lead, found in some gasoline, have

been identified by some state and federal

agencies as causing cancer or reproductive

toxicity. When checking, draining or adding

gasoline, take care not to ingest, breathe the

fumes, or contact gasoline.

0

Used engine oils have been identified by some

state or federal agencies

as

causing cancer or

reproductive toxicity. When checking or

changing engine oil, take care not to ingest,

breathe the fumes, or contact used

oil.

Do

not wok on this equipment when mentally or

physically fatigued, or after consuming any

alcohol

or

drug that makes the operation of

equipment unsafe.

RGA-IN1

iii

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by any means, is strictly prohibited.

Redistribution or publication of this document

by any means, is strictly prohibited.

1

Introduction

GENERAL

This

manual

provides installation guidelines for the

MicroLitem

(KY)

generator set. The generator set

must be installed properly to operate reliably,

quietly, and safely. Read this entire manual before

starting the installation.

For

operation and maintenance procedures,

see

the Operator’s Manual (981

-01

32)

that accompa-

nies each genset.

When properly installed, this generator set meets

or

exceeds the following requirements:

National Electrical Code, NFPA 70-Article 551

ANSVRVIA EGS-1

-

1986, Generator Set

Standard

ANSI AI 19.2/NFPA

501

C

Standard

for

Recreational Vehicles

NFPA Liquefied Petroleum Gas

CSA Electrical bulletin 946

The RV manufacturer and/or the set installer must

comply

with

local codes

such

as

California adminis-

trative Code title 25, which applies to generator set

installation. The RV installer bears sole responsi-

bility for the selection of the appropriate generator

set, installation design, and installation.

Consider the following requirements before install-

ing the set. Each topic is covered in the following

text.

Level and supportive mounting surface

Adequate cooling air

Adequate fresh induction air

Discharge

of

circulated air

Noise levels

Accessibility for maintenance and service

Exhaust connections

Fuel supply

Electrical connections

MicroLite

is

a

trademark of the Onan Corporation

INSTALLATION

CODES

AND SAFETY RECOMMENDATIONS

The following list of Installation Codes and Safety

Recommendations applies to the installation and

operation of

RV

generator sets.

The address

of

each agency is listed

so

that copies of the codes

may be obtained for reference. Installation codes

and recommendations are subject

to

change, and

may vary by location or over time.

The RV

manufacturer and the genset installer bear sole

responsibility for following all applicable codes and

regulations.

1.

ANSI-A119.2 Recreational Vehicle

FMVSS

301

Industry Association

14650

Lee Road

Chantilly VA

22021

2.

NFPA

70

(N.E.C.)

National Fire Protection

NFPA-501 C Association

NFPA 58

470

Atlantic Avenue

3.

CSA Electrical Canadian Standards

Boston MA

02210

Bulletin

#946

Association, Housing and

Construction Materials

Section

178 Rexdale Blvd.

Rexdale, Ontario,

Canada M9W

1

R3

4.

California State of California

Administrative Documents Section

Code

-

Title

25

Chapter

3

North Highlands, CA

P.O. Box 101

5

95660

This manual contains information that

is

subject

to

change. For this reason,

use

only the installation

manual supplied

with

the generator set for the

installation.

Incorrect installation, service, or

replacement

of

park

can

result in severe

personal

injury,

death and/or equipment

damage.

Sewice

personnel

must

be

qualified

to

perform

electrical and/or mechanical

component installation.

1

-1

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by any means, is strictly prohibited.

COMPONENT

LOCATIONS

The standard control panel and routine mainte-

nance items are located behind the access cover

(Figure

1-1).

To

remove the access cover:

Rotate the fasten-

ers on the

access

cover onequarter

turn

clockwise

so

the arrows point to the right. Pull the top

of

the

cover away from the housing.

To

secure the access cover;

Position the bottom

of

the cover over the base. Push the top

of

the

cover in and

turn

fasteners onequarter

turn

coun-

terclockwise

so

the arrows point up.

L

.

'

1-1

Operation

of

the generator set with the access cover removed can result in severeper-

sonal injury or equipment damage.

Hot

components are exposed when the access cover is removed

and generator set cooling air does not circulate properly.

Do

not operate the generator set with the

access cover removed.

AC CONDUIT

CONNECTlON

sTART/sTOP

SWrrcH

NEGATIVE

(-)

CONNECllON

MU-

QNSIDE COVER)

i

-

SPARK

PLUG

ACCESS

DRAIN

ON

BOlTOM

(NOT

SHOWN)

CARBURETOR QUARER-TURN

\

ALTITUDE

FASTENERS

CIRCUIT

BREAKER

ACCESS

COVER

P-

AGURE

1-1.

MICROLITE

(KY)

GENERATOR

SET

COMPONENT LOCATIONS

1

-2

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by any means, is strictly prohibited.

2.

Specifications

.

~

MODEL

GENERATOR

Generator Type

Frequency (Hertz)

Power (Watts)

Voltage

Current (Amperes)

ENGINE

Engine Model

Engine Type

Engine Speed

Ignition Type

Fuel

Engine Oil Capacity

Battery Requirements:

Battery

Size

Cold Cranking Amps

Spark Plug Gap

Average Fuel Consumphn:

No

Load

Half Load

Full Load

GENERATOR SET

DETAILS

Dimensions:

Length

Width

Height

Weight

Air Requirements:

Combustion

Engine/Generator Cooling

Fuel

Pump

Lift

4000

KY

Onan? Revolving Field, 2-Pole

60

4000

1 20

33.3

Onan E095H-G

4-StrokeY Single Cylinder,

OHV

3600 rpm

Electronic Magneto (Breakerless)

Gasoline

1.7

qt

(1.6

L)

12-Volt

360 (450 Below 32OF [OOC])

0.025 in. (0.64 mm)

0.15

gph

(0.57

Uh)

0.40

gph (1.51 Uh)

0.66 gph (2.5 Uh)

30

in.

(762 mm)

19.4 in. (493 mm)

13.8 in. (350.2 mm)

168

Ib

(76.2

kg)

19 ftVrnin (0.54 m3/min)

300 ftWnin (8.5 m3/min)

3

ft

(0.91

m]

3600

KY

(LP)

Onan

,

Revolving Field, 2-Pole

60

3600

120

30

Onan E095H-G

4-Stroke, Single Cylinder,

OHV

3600

rpm

Electronic Magneto (Breakerless)

LPG Vapor

(1

1 inches

W.C.)

1.7

qt

(1.6 L)

12-Volt

360

(450

Below 32OF

[OOC])

0.025 in. (0.64 mm)

0.35 gph (0.54 Uh)

0.54 gph

(2

Uh)

0.82 gph (3.1 Uh)

30

in. (762 mm)

19.4 in. (493 mm)

13.8 in. (350.2 mm)

168

Ib

(76.2

kg)

19 ftVmin (0.54 m3/min)

300

ftVmin

(8.5

@/inin)

-

Redistribution or publication of this document

by any means, is strictly prohibited.

Redistribution or publication of this document

by any means, is strictly prohibited.

3.

SteD-Bv-SteD

Installation

Outline

INTRODUCTION

This section is a step-by-step overview of

a

typical

installation. This section includes:

0

Preparation

0

Compartment Mounting

0

Under-Floor Mounting

Connecting to Vehicle Systems

0

Exhaust System

Review this section, then refer to the detailed

instructions that are given in sections four through

eight for specific procedures and important safety

precautions before starting the installation. The

installer

is

responsible for complying with all appli-

cable installation codes and safety requirements.

PREPARATION

1.

Remove the wooden shipping crate by prying

the bottom of the crate's sides and ends out

from the wooden skid base. Carefully

lift

the

crate

off

the genset and discard.

Remove the plastic bag covering the genset

and collect loose shipped items, like the

Operator's Manual, and add them to the

vehicle documentation package.

2.

Remove the mounting bolts that secure the

wooden skid

to

the ends of the genset base.

FIGURE

3-1.

CRATE

REMOVAL

GENSET

4

-

SHIPPING

I

FIGURE

3-2.

SKID

BASE REMOVAL

3-1

Redistribution or publication of this document

by any means, is strictly prohibited.

COMPARTMENT MOUNTING

Install the generator set in its own compartment. If

any

part

of the compartment is above the vehicle

floor,

separate the compartment

from

the living

quarters with vapor-tight walls. Refer to the

Mount-

ing

section for compartment construction details.

Vehicles

that are unusually

sensitive

to

vlbration

may

require

secondary

Isolatlon and a

larger

compartment.

lgWAR"GJExhaust

gases present the

hazard

of

severe personal Injury

or

death.

Make the

compatfment

walls

vapor tlght to the inferior

of

the vehicle

to

prevent

exhaust

fumes from

enferlng fhe llvlng quarters.

The generator set requiresan unobstructed air inlet

of

at least

40

square inches

(258

cm2). Referto the

Mounting

and

Ventilation

section for details.

Pro-

vide

an

adequate genset access for maintenance

(1

1.25

X

19.5

inch minimum opening) and

service

removal either through the door or out the

bottom.

1.

Carefully measure the compartment size to

make sure there

will

be

proper clearance for

the generator set.

Figure

3-3

shows the

compartment dimensions. Add

1/2

inch to

compartment depth

if

1/2-inch insulation is

used

inside the door.

Allowing one to

two

inches

of

added space on

the left side of the compartment will make

electrical

and fuel connections easier.

2.

Put

holes

in

the bottom of the compartment for

genset mounting, air outlet and

oil

drain

(Figure

3-4).

If

the

bottom

of

the

compartment

is wooden, remove the wooden section under

compartment and replace

it

with

a

sheet metal

floor and an adequate steel support

frame.

(Refer to Onan template

number

539-1383).

NFPA70

@Ea

551-30

(d)

~

225wh--

I

II

dn

MINIMUM

COMPARTMENT

DIMENSIONS

FIGURE

3-3.

COMPARTMENT

DlMENSlONS

DMNAGE

OIL

GENSET

\

I

/

HOLES

DRAIN

MOUNTING

AIR

OUTLET

USE

TEMPLATE

OR

SEE

FIGURE

4-2

uiw6

FIGURE

34.

COMPARTMENT

FLOOR

TEMPLATE

3-2

Redistribution or publication of this document

by any means, is strictly prohibited.

3.

Put

holes in the compartment to run connec-

tions for the fuel line, battery cable, remote

control harness and

AC

conduit. Design holes

so

they

will

not chafe or restrict the lines.

If the remote control harness or AC conduit go

directly into the interior

of

the vehicle, seal

around the wires and inside the conduit to

prevent the passage of exhaust gases. The

fuel line must not be routed through the interior

of the vehicle.

4.

Mount the generator set in the compartment

with four 5/16-16 screws. Screw length must

not protrude more than I/Z-inch

(13

mm)

through the genset base. The exposed above

floor section of exhaust pipe must

be

shielded

with the Onan-supplied exhaust shield.

5.

Proceed to Connecting

To

Vehicle Systems

(page

3-5).

UNDER-FLOOR MOUNTING

An optional kit

is

required for under-floor mounting.

Support brackets are used to suspend the genset

below

the floor of the vehicle. Refer to the

instructions that are supplied with the

kit

for specific

installation instructions and important safety

precautions.

For

additional under-floor mounting

information refer to the

Mounting

section.

1.

Use

the template to locate the holes in the

vehicle support structure. (Reference Onan

template number

539-1

382).

-1

Fallure

to

provlde an adequate

support

structure

can

resuIt In severe

personal Injuv, death, and/or quIpent

damage. Carefully follow the Under-FIoor

HousIng

kif

Installation instrvctions and

provlde an adequate

support

structure.

Use

spcifled

hardware and tighten all

mounting hardware

to

the recommended

torque

seftlngs.

LOCATE

FUEL

AND

ELECTRICAL

LINE

ENTRANCE HOLES IN

SHADED

AREA

UlmM

I

FIGURE

3-5. GENSET

TO VEHICLE

SYSTEMS

CONNECTIONS

I12

INCH

luAx

PROTRUSION

I1

SUPPORT

THICKNESS

5/16-16

SCREW

flGURE

3-6.

COMPARTMENT MOUNTING

0.406

IN.

HOLES

(4)

FOR

3/8

BOLTS

Ml88E

FIGURE

3-7.

UNDER-FLOOR MOUNTING

TEMPLATE

3-3

Redistribution or publication of this document

by any means, is strictly prohibited.

2.

If

the areaabove the compartment

is

made

of

a

wood

product, you must install

a

26gauge

(0.02-inch) galvanized metal plate (or equiva-

lent) above the genset.

3.

Assemble the Under-Floor Housing kit accord-

ing to the instructions supplied with the

kit.

Se-

curely mount hanger brackets and side panels

to the under-floor support structure.

-1

Dropping ihegeneratorset can

cause

severe personal injury or death.

Make sure no onemoves the vehicle during

insWatlon and

keep

feet and hands

clear

durlng Ins fallaiion.

4.

Assemble the front and back rails to the gen-

set.

Use

z

forklift

to carefully raise the genset

into position in the support frame. Secure the

rails to the support frame with the mounting

hardware included in the Under-Floor Housing

kit.

5.

Proceed to the next

section

on connecting to

the vehicle systems.

NFPA

70

(NEC)

551

-30

(9

,id@&

rLI,

-

---e

AREA

ABOVE

SET,

APPROX

20

INCH

X

30

INCH,

MUST

BE

METAL

FIGURE

3-8.

UNDER-FLOOR

MOUNTING

KIT

YlIM-1

WITH

METAL

CEILING

(NOT

SUPPLIED

WITH

KIT)

FIGURE

3-9.

UNDER-FLOOR

MOUNTING

KIT

,

FIGURE

3-10.

UNDER-FLOOR

INSTALLATION

3-4

Redistribution or publication of this document

by any means, is strictly prohibited.

CONNECTING TO

VEHICLE

SYSTEMS

1.

Route fuel line separate from electrical wires or

separate them with conduit or other sheathing.

/aWAR”GI

Fuel presents the hazard of fire

or explosion that can result in severe

personal

injury or death.

Do

not smoke or

allow any flame, spark, pllot light,

arc-producing equipment or other ignition

sources near fuel or in the installa tlon area.

Read the important safefy precautions

in

the Fuel Systems section.

2.

Gasoline Fuel:

Connect 1/4-inch

I.D.

fuel

hose (type

SAE

30-R7)

to the barb fitting on the

generator set.

LPG

Fuel:

Connect 3/8-inch

I.D.

fuel hose

(see

LPG

Fuel

Sysfem)

to

the

barb

fitting

on

the generator set.

Secure

fuel

hose to

barb

fitting with a stainless

steel

clamp

(worm-gear type).

Do

not

over

tighten clamp or hose could be damaged.

3.

Install

a

listed 1/2-inch flexible conduit over the

AC

wiring. (Use water-tight conduit

for

under-

floor mounting.) Secure the conduit to the

fitting on the generator set.

Accidental starting can cause

severe personal injury

or

death.

Do

not

connect the battery cables

to

the

genset

startlng battery until instnrcted to in the

Initial

Start

and Checks section.

4.

Remove the service access cover. Route the

battery positive

(+)

cable through the access

hole in the left side

of

the housing. Connectthe

battery positive

(+)

cable to the

B+

connection

on

the

start

solenoid.

BAlTERY

POSITIVE

(+)

CABLE

.I

FUEL

LINE

u1m

I

FIGURE

3-11.

FUEL

AND

ELECTRIC LINES

FIGURE

3-12.

FUEL LINE CONNECTION

NFPA

70

(NEC)

551-30

(e)

,

FIGURE

3-13.

AC CONDUIT CONNECTION

START

SOLENOID

FIGURE

3-14.

BATTERY

POSITIVE

(+)

CONNECTION

3-5

Redistribution or publication of this document

by any means, is strictly prohibited.

5.

Connect the

battery

negative

(-)

cable

(with

a

W8-inch ring terminal)

to

the ground connec-

tion on the

left

side

of

the

base.

Refer

to

the

Electrical Connections section

for

important

genset grounding instructions.

LQWAR”GjFai1ure to ground the genset

properly can result in Injwy

or

death.

If

the

genset

is

not grounded to the vehicle chas-

sis thtvugh the baitery negative

(-)

cable,

atfach an

8

AWG

equipment ground wlre

between

the vehicle chassis and the bat-

tery negative

(-)

connection.

6.

Route

the

remote control connector through

the

access

opening in the

left

side

of

the

hous-

ing. Connect

the

remote control connector

to

the mating connector inside the genset.

7.

Proceed

to

the next section on connecting

the

exhaust system.

EXHAUST

SYSTEMS

lCgWAR”G1

Ekhaust gas presents the hazard of

severe personal injury or death.

Do

not

temrlnafe the exhaust pipe under the vehicle.

The exhaust

pipe

must not tennlnate

so

#?at

any vent) window,

or

opening Into the llving

area

is

wlthln the triangular

area shown

in

figure

3-21.

Read the important safety

precautions

In the Exhaust

Systems

section.

1.

Connect

the

exhaust pipe

(1

1/2-inch

O.D.

or

1

3/8-inch

I.D.,

installer-supplied)

to

the genset

A

short-radius exhaust elbow

is

supplied with

the

generator set for installations that require

a

tight

turn

of

the exhaust

pipe

at

the

outlet.

Use

the Onan-supplied exhaust

shield

for

compart-

ment

mount installations whenever

the

exhaust

elbow

is

turned

down for through-the-

floor

installations.

with

a

U-bolt

clamp.

FIGURE

3-15.

BAlTERY

NEGATIVE

(-)

CONNECTION

TO

REMOTE

CONTROL

CONNECTION

FIGURE

3-16.

REMOTE CONTROL

CONNECTION

UBOLT

/

EXHAUST

PIPE

EXHAUST

SHIELD

I

~

FIGURE

3-17.

EXHAUST

PIPE

CONNECTION

316

Redistribution or publication of this document

by any means, is strictly prohibited.

2.

Do

not terminate the exhaust

tail

pipe under

the vehicle. The exhaust

tail

pipe

must

terminate

1

inch

(25.4

mm) beyond the side or

end

of

the vehicle.

3.

Support the

tail

pipe as close to the outside of

the vehicle as possible.

4.

Termination of the exhaust tail pipe below the

angle of departure (lowest point

on

rear

of

vehicle to the tire ground contact point) must

be

protected by

a

skid bar, trailer hitch, or

some frame member.

5.

Be aware that any vent, window, or opening

that can

be

opened and that

is

not permanently

sealed from the vehicle living space, can be an

avenue for carbon monoxide.

The

tail

pipe

must not terminate

so

that any

vent, window, or opening into the living area is

within the triangular area shown in Figure

3-21.

6.

Refer to each of the sections in this manual for

detailed installation instructions and for impor-

tant safety precautions. Always

follow

the

procedures in the Initial

Start

and Checks

section when the installation is complete.

ANSI

11 92

PAR.

3-4.3

MTEND

TAlL

PIPE

In

PAST OUTSIDE

EDGE

OF

VEHICLE

OUTSIDE

EDGE

OF

VEHICLE

d

-elk

1"

miin

FIGURE

3-18.

TAIL

PIPE

EXTENSION BEYOND

VEHICLE

LOCATE TAIL PIPE

~

HANGERCLOSE

1

OUSIDE EDGE

OF

VEHICLE

TAIL

PIPE

HANGER

FIGURE

3-19.

EXHAUST PIPE SUPPORT

L

ANSI

119.2 PAR.

3-4.3

LOCATE

TAlL

PIPE

IN

SHADED

..

AREAORABOVE

I

KID

BAR

I

US186

FIGURE

3-20.

TAIL

PIPE

PROTECTION

ANSI

119.2

PAR

3-4.3

NO

OPENINGS

INTO

VEHICLE'S

INTERIOR,

INCLUDING

ENTRY

WORS,

ARE

ALLOWED

IN

THIS

AREA

FIGURE

3-21.

TAIL PIPE LOCATION

3-7

Redistribution or publication of this document

by any means, is strictly prohibited.

Redistribution or publication of this document

by any means, is strictly prohibited.

4.

Mounting

GENERAL

MicroLite generator sets are designed for either

compartment

or

underfloor mounting. Choose the

appropriate part of this section and carefully follow

the instructions. Read any applicable kit instruc-

tions before installing the generator set.

COMPARTMENT MOUNT

In

a

compartment mount, the genset is installed in a

frame that is part of the vehicle. This frame must be

constructed according to safety-approved specifi-

cations (see Compartment Construction

in

this

section).

Vehlcles

that are unusually sensitive to vlbration

may

requlre

secondary isolation and a larger

compartment.

Unless the set will

be

removed from underneath the

vehicle, make the access opening large enough

to

remove the set. Allow enough clearance for

removal

of

the access cover. See Figure

1-1.

Minimum compartment dimensions are shown

in

Figure

4-1.

Clearances between the genset and the

compartment are included

in

these dimensions.

Allow

for

air intake at the front left side of the set and

air

discharge at the bottom of the set. Air inlets to

the set compartment must not allow dirt, rocks,

water,

or

slush to reach the set. Minimize dust and

salt entrance into the compartment. (See

Venfila-

fion

section.)

Exposed above-floor section of exhaust pipe must

be

shielded with the Onan-supplied exhaust shield.

Compartment Constructlon

1.

Install the gen set in its own compartment.

Allow

a

minimum

of Winch

(6.4

mm)

clearance at the front, sides, back and top of

the set. See Figures

4-1

and

4-2.

Allow additional front (service side) clearance

if

the vehicle

air

inlet

is

not aligned with the

genset

air

inlet, to obtain the

minimum

free

air

inlet of 40in2(258 cm2).

Example:

If

the

air

inlet is along the entire bot-

tom front edge of the compartment, increase

the front clearance to

1-113

inches

(34

mm).

40

in2

i30

in (air inlet length)

=

1

-1/3

in.

If insulation is

used

to line

the

compartment,

increase the compartment size to include the

width

of

the insulation.

2.

If

any part of the compartment is above the

vehicle floor, separate the compartment area

from the living quarters and fuel supply with

vapor-tight walls.

3.

Line the compartment walls with 26gauge

galvanized steel

or

a material

of

comparable

strength and fire resistance (see

NFPA

70,

NEC and California Title 25 for complete

detai

Is).

laWAR"GIExhaust gases present the

hazard

of

severe personal

injury

or death.

Make the comparfmenf waiis vapor-tight to

the Interior

of

the vehicle to prevenf

exhaust

fumes

fmm

entering.

4.

Construct

a

compartment

floor

that

will

prevent

oil, fuel

or

water accumulation. Provide

openings in the compartment

floor

according

to the Compartment

Floor

Plan, Figure 4-2.

Do

not

use

absorbent soundproofing material

on the comparlment

floor

or oil and gas could

cause a fire hazard. The floor should have as

few openings as possible, to reduce the noise

level.

5.

Equip the base with an oil drain hole to the

outside of the compartment.

Do

not mount the

exhaust pipe below the oil drain hole.

-1

Fire presents the hazard

of

se-

vere personal injury or death.

Do

not posi-

tlon the exhaust plpe directly below

a

draln

hole. Hot exhaust can ignite

fuel

or

011.

6.

Secure the genset mounting base to the sup-

port

frame with four

5/16-18

UNC

grade

5

screws. The mounting

bolts

must not extend

more than

112

inch

(I

3

mm)

into

the

base.

See

Figures

4-1

and 4-2. Torque

5/16

inch mount-

ing screws to

15

ft

Ibs

(20

Nam).

-1

If

the mounting base

is

not fas-

tened securely to the vehlcle comparfmenf,

road vlbration wiil damage thegenset

com-

ponents.

Use

iong

enough screws

for

at

ieast

1-1/2

threads to extend through the

weld nut.

The

mounting bolts must not ex-

tend more than

7/2

in. (13mm) into the base.

4-1

Redistribution or publication of this document

by any means, is strictly prohibited.

12-9

--.

-I

3.8

M)

.2

IN

I

I-

~

.

-

_.

.

-

NOTES

I

Top

6.4

.25

IN

6.4

.25

IN

pwjINEpD

GENW

6.4

.=IN

SERVICE

SIDE

0.

6.4

.25

IN

BACKSIDE

6.4

.25

IN

HIN

FREE

AIR

uffpkI#.rr

76.2KG168LB

258&

&IN.

4.

MHAusf

PIPE

SHIELD

Musf

BE

USED

Fa?

COCPARTMHT

INSTALL-

ATIONS.

FOR

MDERROOR

INSTALLATIONS

IT

MAY

BE

RMOVED.

~-

5.

HINIPUH INSTAuAfIoN

SIZE

IS

URGERANDVARIESWITH

MOUJTWG

KIT

USED

FIGURE

4-1.

COMPARTMENT

OUTLINE

DRAWING

4-2

Redistribution or publication of this document

by any means, is strictly prohibited.

t-

712

28.0

IN

64'

17

11.6

IN

imr

244.9

3

IN

-292.1

11.5

4x1

Mou

13

PRO

am

-

2nd

OIL

#UIN

-28.8

t

1.14

IN

t

27.3

-I

38.3

1

L:

1.07

IN

1.50

PI

649.7

I

-AIR

INAS

25.6lN

IL

m

-7

I

IN

DRAWING

NOTES

ON

PAGE

4-2

-39.

a

1.57

IN

f

I

214.2

8.4,

IN

13

iP(

#zApuGE

FIGURE

4-2.

COMPARTMENT

FLOOR

PLAN

4-3

Redistribution or publication of this document

by any means, is strictly prohibited.

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